U.S. patent number 10,081,282 [Application Number 15/345,730] was granted by the patent office on 2018-09-25 for inner carrier module for seatback assembly.
This patent grant is currently assigned to Ford Global Technologies, LLC. The grantee listed for this patent is Ford Global Technologies, LLC. Invention is credited to Nicholas Alphonse Billardello, Rodney Charles Brinker, Christian J. Hosbach, Marcos Silva Kondrad, Johnathan Andrew Line.
United States Patent |
10,081,282 |
Line , et al. |
September 25, 2018 |
Inner carrier module for seatback assembly
Abstract
A seatback assembly includes an inner carrier module having an
upper cross member. The upper cross member includes first and
second mounting slots and first and second access apertures
disposed therethrough. A seatback frame assembly includes an upper
frame member with access apertures disposed therethrough. The inner
carrier module is located to a front side of the seatback frame
assembly when a locator member of the inner carrier module is
received in a locating aperture of the seatback frame assembly. The
access apertures of the inner carrier module are aligned with the
access apertures of the seatback frame assembly when the two
components are coupled together. Guide sleeves are received though
the access apertures. A back panel module mounts to a rear side of
the seatback frame assembly, wherein upper hook members of the back
panel are partially received in the mounting slots of the inner
carrier module.
Inventors: |
Line; Johnathan Andrew
(Northville, MI), Kondrad; Marcos Silva (Macomb Township,
MI), Hosbach; Christian J. (Taylor, MI), Billardello;
Nicholas Alphonse (Macomb, MI), Brinker; Rodney Charles
(Eastpointe, MI) |
Applicant: |
Name |
City |
State |
Country |
Type |
Ford Global Technologies, LLC |
Dearborn |
MI |
US |
|
|
Assignee: |
Ford Global Technologies, LLC
(Dearborn, MI)
|
Family
ID: |
62003137 |
Appl.
No.: |
15/345,730 |
Filed: |
November 8, 2016 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20180126886 A1 |
May 10, 2018 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60N
2/809 (20180201); B60N 2/68 (20130101); B60N
2/6009 (20130101); B60N 2/682 (20130101); B60N
2/686 (20130101); B60N 2/80 (20180201); B60N
2/72 (20130101) |
Current International
Class: |
A47C
1/10 (20060101); B60N 2/68 (20060101); B60N
2/80 (20180101); B60R 22/28 (20060101); A47C
7/36 (20060101); A61G 15/00 (20060101) |
Field of
Search: |
;297/391,452.13,452.14,452.18,452.58,452.59,452.65 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Wendell; Mark R
Attorney, Agent or Firm: Chea; Vichit Price Heneveld LLP
Claims
What is claimed is:
1. A seatback assembly, comprising: an inner carrier module having
first and second side members and an upper cross member, the upper
cross member having first and second mounting channels and first
and second access apertures disposed therethrough; a seatback frame
assembly having first and second side frame members and an upper
frame member with first and second receiving apertures disposed
therethrough, wherein the inner carrier module mounts to a front
side of the seatback frame assembly, such that first and second
access apertures of the inner carrier module are aligned with the
first and second receiving apertures of the seatback frame
assembly; and a back panel module having first and second side
members and an upper cross member with first and second upper hook
members disposed thereon, wherein the back panel module mounts to a
rear side of the seatback frame assembly, and further wherein the
first and second upper hook members are partially received in the
first and second mounting channels of the inner carrier module.
2. The seatback assembly of claim 1, including: first and second
guide sleeves received through the first and second access
apertures of the inner carrier module.
3. The seatback assembly of claim 2, wherein the first and second
guide sleeves are operably coupled to the first and second
receiving apertures of the seatback frame assembly.
4. The seatback assembly of claim 3, including: a headrest assembly
having support posts received in the guide sleeves.
5. The seatback assembly of claim 1, including: a locator member
disposed on a rear side of the inner carrier module, wherein the
locator member extends outwardly from the upper cross member of the
inner carrier module.
6. The seatback assembly of claim 5, including: a locating aperture
disposed through the upper frame member of the seatback frame
assembly, wherein the locator member of the inner carrier module is
received in the locating aperture of the seatback frame
assembly.
7. The seatback assembly of claim 6, wherein the locator member
includes a plurality of vertically disposed ribs abutting upper and
lower perimeter edges of the locating aperture.
8. The seatback assembly of claim 7, wherein the locator member
includes a plurality of horizontally disposed ribs abutting first
and second side perimeter edges of the locating aperture.
9. The seatback assembly of claim 1, including: first and second
lower hook members disposed below the upper hook members one the
back panel module; and an upper mounting bracket disposed on the
seatback frame assembly below the upper cross member, the upper
mounting bracket including first and second receiving slots,
wherein the first and second lower hook members of the back panel
module are received through the first and second receiving slots of
the seatback frame assembly.
10. The seatback assembly of claim 1, including: a support cushion
assembly coupled to and supported by the inner carrier module along
a front side of the inner carrier module.
11. The seatback assembly of claim 1, wherein the first and second
side members of the inner carrier module are releasably coupled to
the first and second side members of the back panel module.
12. A seatback assembly, comprising: an inner carrier module having
first and second access apertures and an outwardly extending
locator member; a seatback frame assembly having first and second
receiving apertures, a locating aperture, and first and second
receiving slots, wherein the locator member of the inner carrier
module is received in the locating aperture of the seatback frame
assembly from a front side of the seatback frame assembly to align
the access apertures of the inner carrier module with the receiving
apertures of the seatback frame assembly; and a back panel module
having first and second upper hook members received in the
receiving slots of the seatback frame assembly to mount the back
panel to a rear side of the seatback frame assembly.
13. The seatback assembly of claim 12, wherein the inner carrier
module includes first and second side members, and further wherein
the seatback frame assembly includes first and second side frame
members.
14. The seatback assembly of claim 13, including: first and second
reinforcement brackets coupled to the first and second side members
of the inner carrier module.
15. The seatback assembly of claim 14, wherein the first and second
reinforcement brackets each include outwardly extending upper and
lower anchoring plates coupled to the first and second side frame
members, respectively, of the seatback frame assembly.
16. The seatback assembly of claim 12, wherein the locator member
includes a plurality of ribs abutting upper and lower perimeter
edges of the locating aperture and first and second side perimeter
edges of the locating aperture.
17. The seatback assembly of claim 12, including: first and second
guide sleeves received through the first and second access
apertures of the inner carrier module, wherein the first and second
guide sleeves are operably coupled to the first and second
receiving apertures of the seatback frame assembly.
18. A seatback assembly, comprising: an inner carrier module having
an upper cross member with a substantially vertical front portion
and a substantially horizontal rear portion, wherein first and
second access apertures are disposed through the substantially
horizontal rear portion, and further wherein a locator member
outwardly extends from a rear side of the substantially vertical
front portion; and a seatback frame assembly having an upper frame
member with first and second receiving apertures and a locating
aperture, wherein the locator member of the inner carrier module is
received in the locating aperture of the seatback frame assembly to
align the first and second access apertures of the inner carrier
module with the first and second receiving apertures of the
seatback frame assembly.
19. The seatback assembly of claim 18, including: first and second
guide sleeves received through the first and second access
apertures of the inner carrier module, wherein the first and second
guide sleeves are operably coupled to the first and second
receiving apertures of the seatback frame assembly.
20. The seatback assembly of claim 18, wherein the locator member
includes a plurality of vertical ribs abutting upper and lower
perimeter edges of the locating aperture, and a plurality of
horizontal ribs abutting and first and second side perimeter edges
of the locating aperture.
Description
FIELD OF THE INVENTION
The present invention generally relates to a vehicle seating
assembly, and more particularly, to a vehicle seating assembly
having an inner carrier module that couples to a seat frame
assembly and a back panel using molded in attachment features.
BACKGROUND OF THE INVENTION
Traditional automotive seats are assembled by bringing together
hundreds of parts to be incorporated into a seat structure. This
assembly can be a technical assembly, wherein assembly time is an
important consideration. Thus, the ability to modularize the
seatback assembly process is desired. The present invention
provides for a modularized assembly process that allows for the
seat structure assembly to be sourced to a location independent of
the traditional assembly plant. For use with the present invention,
a new intermediate module design is needed to achieve all of the
structural attachment needs of the seatback, as well as providing a
clean aesthetic for the vehicle seatback.
SUMMARY OF THE INVENTION
One aspect of the present invention includes a seatback assembly
having an inner carrier module with first and second side members
and an upper cross member. The upper cross member includes first
and second mounting slots and first and second access apertures
disposed therethrough. A seatback frame assembly includes first and
second side frame members and an upper frame member with access
apertures disposed therethrough. The inner carrier module is
mounted to a front side of the seatback frame assembly, such that
first and second access apertures of the inner carrier module are
aligned with the first and second access apertures of the seatback
frame assembly when the two components are coupled together. A back
panel module includes first and second side members and an upper
cross member. The upper cross member includes first and second
upper hook members disposed thereon. In assembly, the back panel
module mounts to a rear side of the seatback frame assembly,
wherein the first and second upper hook members are partially
received in the first and second mounting slots of the inner
carrier module.
Another aspect of the present invention includes a seatback
assembly having an inner carrier module with first and second
access apertures and an outwardly extending locator member. A
seatback frame assembly includes first and second access apertures
and a locating aperture. The locator member of the inner carrier
module is received in the locating aperture of the seatback frame
assembly to align the access apertures of the inner carrier module
with the access apertures of the seatback frame assembly.
Yet, another aspect of the present invention includes a seatback
assembly having an inner carrier module with an upper cross member.
The upper cross member includes a substantially vertical front
portion and a substantially horizontal rear portion, wherein first
and second access apertures are disposed through the substantially
horizontal rear portion, and further wherein a locator member
outwardly extends from a rear side of the substantially vertical
front portion. A seatback frame assembly includes an upper frame
member with first and second access apertures and a locating
aperture disposed thereon. The locator member of the inner carrier
module is received in the locating aperture of the seatback frame
assembly to align the first and second access apertures of the
inner carrier module with the first and second access apertures of
the seatback frame assembly.
These and other aspects, objects, and features of the present
invention will be understood and appreciated by those skilled in
the art upon studying the following specification, claims, and
appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a front perspective view of an inner carrier module
according to one embodiment;
FIG. 2A is a front elevational view of the inner carrier modules of
FIG. 1;
FIG. 2B is a rear elevational view of the inner carrier modules of
FIG. 1;
FIG. 3A is a front perspective view of the inner carrier module of
FIG. 1 showing first and second reinforcement brackets exploded
away therefrom;
FIG. 3B is a front perspective view of the inner carrier module of
FIG. 3A with the first and second reinforcement brackets coupled to
the inner carrier module;
FIG. 3C is a rear perspective view of the inner carrier module of
FIG. 3B;
FIG. 3D is a close-up view of the first and second reinforcement
brackets coupled to the inner carrier module of FIG. 3C;
FIG. 4A is a front perspective view of the inner carrier module of
FIG. 3B showing a support cushion assembly exploded away
therefrom;
FIG. 4B is a rear perspective view of the inner carrier module of
FIG. 4A showing the support cushion coupled thereto to from an
assembled front seatback module;
FIG. 5A is a front perspective view of the front seatback module of
FIG. 4B showing a seatback frame assembly exploded away
therefrom;
FIG. 5B is a fragmentary front perspective view of an inner carrier
module coupled to a seatback frame assembly at upper portions
thereof;
FIG. 5C is a fragmentary rear perspective view of the inner carrier
module of FIG. 5B coupled to the seatback frame assembly at middle
portions thereof;
FIG. 6 is an exploded perspective view of a back panel and the
front seatback module of FIG. 4B exploded away from a seatback
frame assembly;
FIG. 7 is perspective view of hooks of the a back panel engaging
mounting slots of an inner carrier module; and
FIG. 8 is a perspective view of an assembled vehicle seat assembly
with a headrest assembly exploded away therefrom.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For purposes of description herein, the terms "upper," "lower,"
"right," "left," "rear," "front," "vertical," "horizontal," and
derivatives thereof shall relate to the invention as oriented in
FIG. 1. However, it is to be understood that the invention may
assume various alternative orientations, except where expressly
specified to the contrary. It is also to be understood that the
specific devices and processes illustrated in the attached
drawings, and described in the following specification are simply
exemplary embodiments of the inventive concepts defined in the
appended claims. Hence, specific dimensions and other physical
characteristics relating to the embodiments disclosed herein are
not to be considered as limiting, unless the claims expressly state
otherwise.
Referring now to FIG. 1, the reference numeral 10 generally
designates an inner carrier module for use in a vehicle seatback
assembly. The inner carrier module 10 includes a front side 10A and
a rear side 10B. The inner carrier module 10 further includes first
and second side members 12, 14 which are generally spaced-apart and
interconnected by upper and lower cross-members 16, 18. Thus, as
shown in FIG. 1, the side members 12, 14 and upper and lower
cross-members 16, 18 generally define a frame structure 20 disposed
around a central aperture or window 22. The inner carrier module 10
is contemplated to be a composite part which is comprised of a
polymeric or injection molded material, such that the inner carrier
module 10 is a unitary part as shown in FIG. 1. The first and
second side members 12, 14 generally include outermost edges 12A,
14A, respectively, and innermost edges 12B, 14B, respectively. The
outermost edges 12A, 14A generally define side perimeters of the
inner carrier module 10, and also form a portion of a releasable
mating joint feature with a back panel module, as further described
below. The first and second side members 12, 14 further include a
plurality of clip embossments 24, which are generally disposed
adjacent to the outer edges 12A, 14A along a periphery of the inner
carrier module 10. As further shown in FIG. 1, the clip embossments
24 of the first and second side members 12, 14 include planar
mounting surfaces 24A which are used to couple the inner carrier
module 10 to a back panel module, as further described below. The
clip embossments 24 are spaced-apart along the first and second
side members 12, 14 with trim cover attachment features 26 disposed
therebetween. Thus, the trim cover attachment features 26 are
disposed along the first and second side members 12, 14 and include
mounting slots 28 disposed therethrough. In assembly, the mounting
slots 28 are used to couple a support cushion assembly to the inner
carrier module 10. As further shown in FIG. 1, inner mounting
structures 30A, 30B are disposed on the innermost edges 12B, 14B of
the first and second side members 12, 14 and are used to couple the
inner carrier module 10 to reinforcement brackets, as further
described below.
With specific reference to the upper cross member 16, the upper
cross member 16 includes a stepped configuration having a
substantially vertical front portion 16A, a substantially
horizontal rear portion 16B, and a substantially vertical upper rim
portion 16C. First and second access apertures 32, 34 are disposed
through the rear portion 16B and are configured to receive guide
sleeves for a headrest assembly to mechanically attach the inner
carrier module 10 to a seat frame assembly, as further described
below. A central receiving slot 36 is also disposed through the
rear portion 16B of the upper cross member 16 and is positioned
between the first and second access apertures 32, 34. First and
second mounting bosses 38, 40 are disposed on the substantially
vertical front portion 16A of the upper cross member 16 and are
used to couple the inner carrier module 10 to a seat frame
assembly. The terms "substantially vertical" and "substantially
horizontal" as used in this disclosure generally indicate portions
of a part that are perpendicular to each other. Thus, while the
inner carrier module 10 can be reclined as used in a seatback
assembly, the specific portions above are identified in the figures
as shown with the inner carrier module 10 in an upright position.
Similar terms are also used to describe parts of a seatback frame
assembly, as further discussed below.
With specific reference to the lower cross member 18, first and
second mounting slots 42, 44 are disposed through opposite sides of
the lower cross member 18 and are used to couple the inner carrier
module 10 to a support cushion assembly, as further described
below. A central clip member 46 is disposed on the lower cross
member 18 and is also used to couple the inner carrier module 10 to
a support cushion assembly.
Referring now to FIG. 2A, the inner carrier module 10 is shown from
the front side 10A and having a suspension assembly 50 that is
coupled to the frame 20 and generally disposed within the window
22. Specifically, the suspension assembly 50 is coupled to the
first and second side members 12, 14 and the upper and lower cross
members 16, 18 at inner portions thereof. The suspension system 50
is configured to support a lumbar portion of a vehicle occupant in
a flexibly resilient manner.
Referring now to FIG. 2B, the rear side 10B of the inner carrier
module 10 is shown, wherein the upper cross member 16 includes
first and second mounting channels 52, 54 disposed on the upper rim
portion 16C of the upper cross member 16. Specifically, the first
and second mounting channels 52, 54 are disposed above the first
and second access apertures 32, 34 which are disposed on the
substantially horizontal rear portion 16B of the upper cross member
16. On the substantially vertical front portion 16A of the upper
cross member 16, a four-way locator member 56 outwardly extends
from the substantially vertical front portion 16A of the upper
cross member 16 and is generally centrally disposed between the
first and second mounting bosses 38, 40. In assembly, the first and
second mounting channels 52, 54 and the four-way locator member 56
are used to couple the inner carrier module 10 to a seat frame
assembly, as well as a back panel module, as further described
below. In FIG. 2B, the lower cross member 18 is shown having
mounting bosses 43, 45 disposed on opposite sides of the lower
cross member 18. The mounting bosses 43, 45 are used to couple the
inner carrier module 10 to a seatback frame assembly, as further
described below.
As further shown in FIG. 2B, the side members 12, 14 of the inner
carrier module 10 include reinforcement ribs 60 which are disposed
in a substantially horizontal manner between the outermost edges
12A, 14A and the innermost edges 12B, 14B of the respective side
members 13, 14. The reinforcement ribs 60 rigidify the inner
carrier module 10 at the side members 12, 14 thereof and provide
increased durability to the overall structure of the inner carrier
module 10.
Referring now to FIG. 3A, the inner carrier module 10 is shown
having reinforcement brackets 70, 72 exploded away therefrom. The
reinforcement brackets 70, 72 are contemplated to be stamped metal
parts which couple to the side members 12, 14 at the upper and
lower inner mounting structures 30A, 30B disposed on the innermost
edges 12B, 14B thereof. The reinforcement brackets 70, 72 include
body portions 74 through which fasteners 76 pass through and couple
to the upper and lower inner mounting structures 30A, 30B of the
side members 12, 14 of the inner carrier module 10. The body
portion 74 further includes a forwardly extending portion 78 and
upper and lower rearwardly extending anchoring plates 80, 82. The
upper and lower anchoring plates 80, 82 extend rearwardly from the
body portion 74 and are configured to couple to a seatback frame
assembly using fasteners 84. On a rear edge 86 of the body portion
74, an inwardly curved portion 88 is disposed which is configured
to align with apertures disposed through the seatback frame
assembly for supporting a cross member therebetween, as further
described below. As further shown in FIG. 3A, the locator member 56
extends outwardly from the rear side 10B of the inner carrier
module 10 at upper cross member 16 and includes a number of
vertically disposed ribs 56A and a horizontally disposed rib 56B.
It is contemplated that the locator member 56 may include any
number of vertical or horizontal ribs in order to effectively
locate the inner carrier module 10 to a seatback frame assembly, as
further described below.
Referring now to FIGS. 3B and 3C, the reinforcement brackets 70, 72
are shown coupled to the side members 12, 14 of the inner carrier
module 10. In use, the reinforcement brackets provide mounting
features to mount the inner carrier module 10 to a seatback frame
assembly to reinforce a connection therebetween and to prevent
squeak and rattle of the seatback components in use.
Referring now to FIG. 3D, the first and second reinforcement
brackets 70, 72 are shown coupled to the side members 12, 14 of the
inner carrier module 10. The upper and lower anchoring plates 80,
82 are shown rearwardly extending from the side members 12, 14
while the body portion 74 of the reinforcement brackets 70, 72 are
shown coupled to the side members 12, 14 via fasteners 76. The
fasteners 76 are received through inner mounting structures 30A,
30B disposed on the side members 12, 14 in assembly.
Referring now to FIG. 4A, an upholstered trim cover 92 is shown
disposed over a support cushion assembly 94. The support cushion
assembly 94 is a contoured component, and the trim cover 92
includes a reciprocal configuration thereto, such that the trim
cover 92 closely covers the contours of the support cushion
assembly 94. The trim cover 92 is contemplated to be comprised of a
fabric, vinyl or leather material, or other like covering material
(or combination thereof), while the support cushion assembly 94 is
contemplated to be comprised of a resilient foam material which may
include areas of varying density or rigidity. The support cushion
assembly 94 is configured to support a back area of a vehicle
occupant in use. In assembly, the trim cover 92 and support cushion
94 are further coupled to and supported by the inner carrier module
10. In FIG. 4A, the support cushion assembly 94 includes a central
portion 95 surrounded by first and second sides 96, 98 and upper
and lower sides 100, 102. The first and second sides 96, 98 are
configured to align with and couple to the first and second side
members 12, 14 of the inner carrier module 10 at attachment
features 26 using clips that couple to mounting slots 28 of
attachment features 26. The upper and lower sides 100, 102 are
configured to align with and couple to the upper and lower cross
members 16, 18 of the inner carrier module 10 in assembly. The
upper side 100 of the front seatback module 90 is contemplated to
include access apertures 104, 106 disposed through the trim cover
92 to provide access to the access apertures 32, 34 disposed
through the horizontal middle portion 16B of the upper cross member
16 of the inner carrier module 10. In this way, guide sleeves (FIG.
5A) can be inserted into the access apertures 32, 34 through the
upper side 100 of the front seatback module 90 to couple the inner
carrier module 10 and the front seatback module 90 to a seatback
frame assembly, as further described below. With reference to FIG.
4B, the inner carrier module 10 is shown coupled to the support
cushion assembly 94 to define an assembled front seatback module
90. Access apertures 104, 106 disposed through the trim cover 92
are shown aligned with the access apertures 32, 34 of the upper
cross member 16 of the inner carrier module 10 as assembled.
Referring now to FIG. 5A, the assembled front seatback module 90
includes the support cushion assembly 94 covered by the trim cover
92. The support cushion 94 and trim cover 92 are coupled to the
inner carrier module 10 for support therefrom. In FIG. 5A, the
front seatback module 90 is shown exploded away from a seatback
frame assembly 110. The seatback frame assembly 110 includes a
front side 110A and a rear side 110B. The seatback frame assembly
110 further includes first and second side frame members 112, 114
which are spaced-apart and interconnected by upper and lower frame
members 116, 118. The interconnection of the side members 112, 114
and the upper and lower frame members 116, 118 generally defines a
frame 120 surrounding a central aperture or window 122. The
seatback frame assembly 110 is contemplated to be pivotally coupled
to a seat frame assembly for supporting a vehicle occupant in
upright and reclined positions. The seatback frame assembly 110 is
contemplated to be comprised of a stamped metal material to provide
the structural support necessary for carrying the load of a vehicle
occupant as well as the vehicle seat components that are coupled to
the seatback frame assembly 110 in use. With specific reference to
the upper frame member 116, the upper frame member 116 includes a
substantially vertical front portion 116A, a substantially
horizontal rear portion 116B and a substantially vertical rim
portion 116C. First and second receiving apertures 132, 134 are
disposed through the substantially horizontal rear portion 116B and
are configured to receive guide sleeves 150, 152 therethrough,
respectively. The substantially vertical front portion 116A
includes a generally centrally disposed locating aperture 136 which
is configured to receive the rearwardly extending locator member 56
of the inner carrier module 10 shown in FIG. 4B. By receiving the
locator member 56 through the locating aperture 136, the assembled
front seatback module 90 is located to the seatback frame assembly
110, thereby aligning other attachment features of the front
seatback module 90, the seatback frame assembly 110, and a back
panel assembly, as further described below. The substantially
vertical front portion 116A of the upper frame member 116 further
includes mounting apertures 138, 140 which are configured to align
with first and second mounting bosses 38, 40 disposed on the
vertical front portion 16A of the inner carrier module 10 as shown
in FIG. 1. Disposed below the upper frame member 116, an upper
mounting bracket 116D is disposed having first and second receiving
slots 142, 144 for receiving hooks from a back panel assembly
therethrough, as further described below. As further shown in FIG.
5A, the side frame members 112, 114 generally include inset body
portions 112A, 114A having upper and lower mounting apertures 146,
148 which are disposed above and below a receiving aperture 149 on
each side frame member 112, 114. In assembly, the receiving
apertures 149 are configured to receive a cross member for further
rigidifying the structure of the seatback frame assembly 110. The
cross member is contemplated to span the distance between the
spaced-apart first and second side frame members 112, 114 through
the window 122 defined by the frame 120 of the seatback frame
assembly 110. The mounting apertures 146, 148 are configured to
align with the rearwardly extending upper and lower anchoring
plates 80, 82 of the reinforcement brackets 70, 72 using fasteners
84, as best shown in FIG. 5C.
With specific reference to the lower frame member 118, mounting
apertures 143, 145 are shown disposed on opposite side of the lower
frame member 118 and are used to couple the seatback frame assembly
110 to the inner carrier module 10 at mounting slots 42, 44
disposed on the lower cross member 18 of the inner carrier module
10 (FIG. 3A).
With specific reference to the first and second guides sleeves 150,
152, each guide sleeve 150, 152 includes a head portion 154 with a
downwardly extending hollow shaft portion 156 coupled thereto. The
downwardly extending shaft portion 156 includes a clip member 158
that is used to clip the guide sleeves 150, 152 to the seatback
frame assembly 110 at receiving apertures 132, 134. In assembly,
the guide sleeves 150, 152 are received through the access
apertures 104, 106 of the support cushion assembly 94 at the upper
portion 100 thereof. The guide sleeves are then received through
the first and second access apertures 32, 34 of the upper cross
member 16 of the inner carrier module 10 as shown in FIG. 1.
Finally, the guide sleeves 150, 152 are received through the
receiving apertures 132, 134 of the upper frame member 116 of the
seatback frame assembly 110, wherein clip members 158 clip to the
receiving apertures 132, 134 of the upper frame member 116 of the
seatback frame assembly 110. With the guide sleeves 150, 152 in
place, the front seatback module 90 is mechanically coupled to the
seatback frame assembly 110 without the need for screws, bolts, or
other like fasteners. In this way, the front seatback module 90 can
be coupled to the seatback frame assembly 110 in a quick and
efficient manner before being sent to final assembly.
Referring now to FIG. 5B, the support cushion assembly 94 has been
removed to show the inner carrier module 10 as coupled to the
seatback frame assembly 110. With the inner carrier module 10
mounted over the front side 110A of the seatback frame assembly
110, the first and second access apertures 32, 34 of the inner
carrier module 10 are shown disposed around the receiving apertures
132, 134 of the seatback frame assembly 110. In this way, the guide
sleeves 150, 152 are provided access through the access apertures
32, 34 of the inner carrier module 10 to the receiving apertures
132, 134 of the seatback frame assembly 110. The clip members 158
of the first and second guide sleeves 150, 152 can then clip to the
receiving apertures 132, 134 of the seatback frame assembly
110.
With further reference to FIG. 5B, the locator member 56 is shown
in phantom as rearwardly extending from the rear side 10B of the
inner carrier module 10 at the upper cross member 16. The locator
member 56 is received in the locating aperture 136 of the seatback
frame assembly 110. The locator member 56 includes a plurality of
vertically disposed ribs 56A abutting upper and lower perimeter
edges 136A, 136B of the locating aperture 136. In this way, the
locator member 56 vertically aligns and locates the inner carrier
module 10 to the seatback frame assembly 110 along a z-axis.
Further, the locator member 56 includes a plurality of horizontally
disposed ribs 56B abutting first and second side perimeter edges
136C, 136D of the locating aperture 136. In this way, the locator
member 56 horizontally (or latterly) aligns and locates the inner
carrier module 10 to the seatback frame assembly 110 along an
x-axis. In this way, the locator member 56 is a 4-way locating
member given the 4-way engagement with the four side edges
136A-136D of the locating aperture 136. When the inner carrier
module 10 is located to the seatback frame assembly 110 using the
interaction of the locator member 56 and locating aperture 136 in
an abutting engagement therewith, the access apertures 32, 34 of
the inner carrier module 10 are aligned with the receiving
apertures 132, 134 of the seatback frame assembly 110. With the
access apertures 32, 34 of the inner carrier module 10 aligned with
the receiving apertures 132, 134 of the seatback frame assembly
110, the guide sleeves (FIG. 5A) can be received and coupled
thereto.
Referring now to FIG. 5C, the inner carrier module 10 is shown
coupled to the seatback frame assembly 110 using fasteners 84 which
couple the inset body portions 112A, 114A of side frame members
112, 114 to reinforcement brackets 70, 72 using fasteners 84
disposed through the upper and lower anchoring plates 80, 82 which
rearwardly extend from the reinforcement bracket 70, 72. As further
shown in FIG. 5C, the curved portion 88 of the outer edge 86 of the
reinforcement bracket 72 is shown to align with receiving aperture
149 of the side frame member 114. In this way, the reinforcement
brackets 70, 72 can be coupled to a cross member disposed between
the receiving apertures 149 of the side frame members 112, 114 to
reinforce the same.
Referring now to FIG. 6, the seatback frame assembly 110 is shown
having the inner carrier module 10 exploded away in a forward
direction therefrom. A back panel assembly or module 210 is shown
exploded away in a rearward direction from the seatback frame
assembly 110. The inner carrier module 10 is shown from the rear
side 10B thereof. The rear side 10B of the inner carrier module 10
couples to the front side 110A of the seatback frame assembly 110
in assembly. The back panel module 210 includes a front side 210A
and a rear side 210B. The front side 210A of the back panel module
210 is configured to couple to the rear side 110B of the seatback
frame assembly 110. The back panel module 210 further couples to
the inner carrier module 10 around the seatback frame assembly 110,
as further described below.
As shown in FIG. 6, the back panel module 210 includes first and
second side members 212, 214 which are generally spaced-apart and
interconnected by upper and lower cross members 216, 218. The back
panel module 210 further includes a central panel 222 that is
generally surrounded by the first and second side members 212, 214
and the upper and lower cross members 216, 218. The back panel
module 210 is contemplated to be a composite part which is
comprised of a polymeric or injection molded material, such that
the back panel module 210, and the features thereof, form a unitary
part as shown in FIG. 6. The first and second side members 212, 214
include perimeter edges 212A, 214A having integrally molded clip
members 224 disposed therealong. The clip members 224 are
configured to clip to the planar mounting surfaces 24A of the clip
embossments 24 disposed along the side members 12, 14 of the inner
carrier module 10. With the back panel module 210 clipped to the
inner carrier module 10, the side members 212, 214 generally cover
the side frame members 112, 114 of the seatback frame assembly 110.
In this way, the back panel module 210 couples to the inner carrier
module 10 around the seatback frame assembly 110. Put another way,
the seatback frame assembly 110 is disposed between the inner
carrier module 10 and the back panel module 210 when the inner
carrier module 10 is coupled to the back panel module 210.
With specific reference to the upper cross member 216 of the back
panel module 210, first and second upper hook members 252, 254 are
shown having distal ends 252A, 254A. In assembly, the distal ends
252A, 254A of the upper hook members 252, 254 are configured to be
received in the mounting channels 52, 54 disposed on the upper
cross member 16 of the inner carrier module 10. The upper cross
member 216 of the back panel module 210 further includes lower
first and second hook members 242, 244 which include distal ends
242A, 244A. In assembly, the lower first and second hook members
242, 244 are configured to be received through receiving slots 142,
144 of the seatback frame assembly 110. In this way, the back panel
module 210 couples to both the seatback frame assembly 110 and the
inner carrier module 10.
With specific reference to the lower cross member 218 of the back
panel module 210, first and second clip members 243, 245 are
configured to clip to mounting apertures 143, 145 disposed on the
lower frame member 118 of the seatback frame assembly 110.
As noted above, the coupling of the back panel module 210 to the
inner carrier module 10 is a releasable coupling, particularly at
the coupling of the side members 12, 14 of the inner carrier module
10 and the side members 212, 214 of the back panel module 210.
Specifically, the integrally molded clip members 224 of the back
panel module 210 releasably couple to the planar mounting surface
24A of the clip embossments 24 which are integrally molded along
the side members 12, 14 of the inner carrier module 10. Given the
releasable coupling between the inner carrier module 10 and the
back panel 210, a side air bag can deploy through the releasable
coupling in order to inflate an airbag along a side portion of a
vehicle seat. An airbag module can be mounted to the inset body
portion 112A or 114A of the seatback frame assembly 110, such that
the airbag module would be aligned with a scene disposed between
the releasably coupled back panel module 210 and the inner carrier
module 10.
In assembling an entire vehicle seatback, the inner carrier module
10 will be coupled to the support cushion assembly 94 to create the
front seatback module 90. The front seatback module 90 will then be
coupled to the seatback frame assembly 110 by first locating the
locator member 56 of the inner carrier module 10 to the locating
aperture 136 disposed on the substantially vertical front portion
116A of the upper frame member 116 of the seatback frame assembly
110. By locating the locator member 56 to the locating aperture
136, the access apertures 32, 34 of the inner carrier module 10
should align with the receiving apertures 132, 134 of the seatback
frame assembly 110 in a manner as shown in FIG. 5B. With the inner
carrier module 10 coupled to the seatback frame assembly 110,
fasteners 84 of the reinforcement brackets 70, 72 can be driven
into the mounting apertures 146, 148 of the side frame members 112,
114 of the seatback frame assembly 110. With the inner carrier
module 10 fixedly coupled to the seatback frame assembly 110, the
back panel module 210 can then couple to the inner carrier module
10 and the seatback frame assembly 110.
With specific reference to FIG. 7, the first and second upper hook
members 252, 254 disposed on the upper cross member 216 of the back
panel module 210 are shown ready to be received in the mounting
channels 52, 54 disposed on the upper cross member 16 of the inner
carrier module 10. Specifically, the distal ends 252A, 254A of the
first and second upper hook members 252, 254 are received in the
mounting channels 52, 54 of the inner carrier module 10 along the
path as indicated by arrows 259. In the embodiment shown in FIG. 7,
the first and second upper hook members 252, 254 are shown as a
series of spaced-apart ribs 263, 265 to provide added rigidity to
the first and second upper hook members 252, 254.
Referring now to FIG. 8, an assembled vehicle seat 260 is shown
having a seat portion 262 and an assembled seatback portion 264.
The assembled seatback portion 264 is provided by the coupling of
the front seatback module 90 the seatback frame assembly 110 and
the back panel module 210. A headrest assembly 266 is shown
exploded away from an upper portion of the assembled seatback
portion 264. With the headrest assembly 266 exploded away from the
upper portion of the assembled seatback portion 264, the head
portions 154 of the first and second guide sleeves 150, 152 are
shown. The headrest assembly 266 includes first and second support
posts 268, 270 which are received within the hollow shaft portions
156 (FIG. 5A) of the first and second guide sleeves 150, 152 and
vertically adjustable within. The headrest assembly 266 further
includes a headrest bun 267 that is supported by the first and
second support posts 268, 270.
It will be understood by one having ordinary skill in the art that
construction of the described invention and other components is not
limited to any specific material. Other exemplary embodiments of
the invention disclosed herein may be formed from a wide variety of
materials, unless described otherwise herein.
For purposes of this disclosure, the term "coupled" (in all of its
forms, couple, coupling, coupled, etc.) generally means the joining
of two components (electrical or mechanical) directly or indirectly
to one another. Such joining may be stationary in nature or movable
in nature. Such joining may be achieved with the two components
(electrical or mechanical) and any additional intermediate members
being integrally formed as a single unitary body with one another
or with the two components. Such joining may be permanent in nature
or may be removable or releasable in nature unless otherwise
stated.
It is also important to note that the construction and arrangement
of the elements of the invention as shown in the exemplary
embodiments is illustrative only. Although only a few embodiments
of the present innovations have been described in detail in this
disclosure, those skilled in the art who review this disclosure
will readily appreciate that many modifications are possible (e.g.,
variations in sizes, dimensions, structures, shapes and proportions
of the various elements, values of parameters, mounting
arrangements, use of materials, colors, orientations, etc.) without
materially departing from the novel teachings and advantages of the
subject matter recited. For example, elements shown as integrally
formed may be constructed of multiple parts or elements shown as
multiple parts may be integrally formed, the operation of the
interfaces may be reversed or otherwise varied, the length or width
of the structures and/or members or connector or other elements of
the system may be varied, the nature or number of adjustment
positions provided between the elements may be varied. It should be
noted that the elements and/or assemblies of the system may be
constructed from any of a wide variety of materials that provide
sufficient strength or durability, in any of a wide variety of
colors, textures, and combinations. Accordingly, all such
modifications are intended to be included within the scope of the
present innovations. Other substitutions, modifications, changes,
and omissions may be made in the design, operating conditions, and
arrangement of the desired and other exemplary embodiments without
departing from the spirit of the present innovations.
It will be understood that any described processes or steps within
described processes may be combined with other disclosed processes
or steps to form structures within the scope of the present
invention. The exemplary structures and processes disclosed herein
are for illustrative purposes and are not to be construed as
limiting.
It is also to be understood that variations and modifications can
be made on the aforementioned structures and methods without
departing from the concepts of the present invention, and further
it is to be understood that such concepts are intended to be
covered by the following claims unless these claims by their
language expressly state otherwise.
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